Mobile Carpet Display System

ABSTRACT

A mobile system for the display of multiple carpet samples in a concise and orderly array which are securely mounted within a convenient unitary carrier, yet which are readily accessed when comparing each of the samples to the decor at locations remote from the retail outlet. In the present system, the carpet samples are individually affixed to a strong, but light-weight carrier comprised substantially exclusively of paperboard and which is particularly resistant to flexing, tearing or rupture in the course of conveyance of the samples to and from a retail outlet and/or when exposing each sample for evaluation in the actual environment within which the carpet is intended to be installed.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not Applicable

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

FIELD OF INVENTION

This invention relates to the display of carpet samples, particularly displays of multiple carpet samples as a unit.

BACKGROUND OF INVENTION

By reason of their bulky nature, carpets are most commonly displayed in the form of relatively small samples at a retail (or wholesale) outlet for evaluation by prospective purchasers. It is not unusual for a retail outlet to display multiple relatively small samples of available carpets in groupings so that a potential purchaser may view multiple carpet designs without meandering among large bulky displays of carpets. Even so, there is little, if any, opportunity for a potential purchaser of carpet to “match” a carpet design to other decorative features of a room, office or other enclosure where the carpet is to be installed.

Even when relatively small size samples of a carpet are made available for viewing by a potential purchaser, the bulky nature of the carpet samples and their weight may inhibit or even preclude the potential purchaser from taking multiple carpet samples to their home or office for evaluation purposes, particularly for matching of a carpet to existing decorative features of the house or office. Moreover, even small carpet samples can be flexible and difficult to handle when attempting to position a carpet sample alongside one or more of the existing decorative features of a home or office in a manner as allows the purchaser to make their choice of carpet.

SUMMARY OF INVENTION

In accordance with one aspect of the present invention there is provided a mobile system for the display of multiple carpet samples mounted in a concise and orderly array on a convenient unitary carrier, yet which are readily accessed when comparing each of the samples to the decor at locations remote from the retail outlet. In the present system, the carpet samples are individually affixed to a strong, but light-weight carrier comprised substantially exclusively of paperboard and which is particularly resistant to flexing, tearing or rupture in the course of conveyance of the multiple samples to and from a retail outlet and/or when exposing each sample for evaluation in the actual environment within which the carpet is intended to be installed.

In the present system, the carrier preferably comprises a unitary carrier formed from a laminate of paperboard which includes specifically selected components that are combined in a specifically selected order of formation and of specifically selected paperboard elements which in combination exhibit enhanced strength, rigidity and minimized overall weight of the carrier. The present invention envisions multiple sizes of carriers, depending in major part by the number and/or size of samples which are to be affixed to the carrier for display purposes. The carriers of the present invention further may be designed as a planar panel onto which the samples are affixed, or “book” of samples, or some geometrical combination intermediate a folding book and a planar panel. In the instance of planar panel carriers, the top end of the carrier is folded over and provided with means for grasping the carrier with a handle for transport of the carrier and its samples. In a “book” type carrier, the closed book is of a size which is readily carried by a prospective purchaser.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a schematic representation of one embodiment of a multilayered laminate formed essentially of paper and adapted to be formed into a carrier embodying various features of the present invention;

FIG. 2 is an enlarged partial end view of the laminate depicted in FIG. 1 minus the overwrapping outer layer of FIG. 1;

FIG. 3 is an enlarged sectional view of a corner of the laminate depicted in FIG. 1 and taken generally along the line 3-3 of FIG. 1;

FIG. 4 is a schematic representation of one embodiment of a cut unit of a laminate as depicted in FIG. 1 and including an overwrapping outer layer of paperboard;

FIG. 5 is a partial sectional view of the cut unit of FIG. 4 taken generally along the line 5-5 of FIG. 4:

FIG. 6 is a schematic representation of one embodiment of a carrier formed from a cut unit as depicted in FIG. 1 and embodying various features of the present invention;

FIG. 7 is a further schematic representation of the carrier depicted in FIG. 6 and depicting intersecting ribs defining individual panes adapted to each receive a carpet sample therein;

FIG. 8 is a schematic representation of one embodiment of a folding carrier embodying various features of the present invention;

FIG. 9 is a schematic representation of a cut unit of laminate useful in forming the folding carrier depicted in FIG. 8;

FIG. 10 is a schematic representation of the front surface of the cut unit depicted in FIG. 9 and showing one array of carpet samples mounted thereon;

FIG. 11 is a top view of the cut unit depicted in FIG. 10; and,

FIG. 12 is an end view of a folded carrier formed from the cut unit depicted in FIG. 9.

DETAILED DESCRIPTION OF INVENTION

Of essence in the present invention is the construction of a light-weight, carrier which desirably is unitary, non-flexing, tear and puncture resistant and sufficiently strong as to support multiple carpet samples in a planar attitude for transport between at least a retail outlet and a location remote from such retail outlet, commonly repeated ones of such transport events by various prospective consumers.

In accordance with one aspect of the present invention, and referring to several Figures initially, there is provided a carrier 12 comprising a laminate 14 of paper (which term includes the commonly known types of paper sheet material employed in corrugated laminates unless the context indicates otherwise). This carrier includes a planar central core 16 of a first layer 18 of corrugated paperboard having a first set of physical and mechanical, a second layer 20 of corrugated paperboard having a second and differing set of physical and mechanical characteristics, and an intermediate inner layer of linerboard. This combination is bonded together employing conventional gluing techniques wherein the valleys 24 of the flutes 26 of the first layer of corrugated material and the peaks 28 of the flutes 30 of the second layer 20 of corrugated paperboard are bonded to respective opposite surfaces 31,33 of the intermediate inner layer 22 of linerboard. As depicted, the flutes of the two layers of corrugated paperboard are aligned generally parallel to one another and perpendicular to the longitudinal centerline 35 of the laminate.

As depicted in FIGS. 2 and 3, in one embodiment, the planar central core 16 is faced on the outer top surface 32 thereof with a top layer of linerboard 34 and is faced on its opposite outer bottom surface 36 with a bottom layer 38 of linerboard. In the depicted embodiment, the top layer of linerboard is about 0.18 inch thick and of a Mullen of about 69 lbs. The bottom layer of linerboard is of about 0.18 inch thickness and exhibits a Mullen of about 69 lbs. The top layer 34 of linerboard is bonded to the peaks 40 of the flutes 26 of the first layer of corrugated paperboard core. The bottom layer of linerboard is bonded to the flutes 42 of the bottom layer 38 of corrugated paperboard, thereby integrating the multiple layers into a laminated planar core employing conventional gluing techniques. In the depicted embodiment of FIGS. 1 and 5 there is shown an optional further bottom layer 44 of linerboard which is substantially identical to the bottom layer 38 of linerboard that is bonded to the second layer of corrugated paperboard.

As depicted in FIG. 2, the first layer 18 of corrugated paperboard includes flutes 26 having peaks 27 and valleys 24 which are spaced apart by a first distance. In one embodiment, these flutes exhibit a height of about 0.085 inches and are substantially equally spaced apart at about 8 to about 12 flutes per lineal inch. In this embodiment, the flutes 30 of the second layer of corrugated paperboard include peaks 28 and valleys 29 which are substantially equally spaced apart by a second distance which is significantly less than the spatial distance between the flutes of the first layer of corrugated paperboard, namely, spaced apart by about 15 and about 20 flutes per lineal inch. Further, the thickness of the paperboard from which the flutes of the first layer are corrugated paperboard are formed is of a first thickness which is greater than the thickness of the paperboard from which the flutes of the second corrugated layer is formed. For example, the thickness of the paperboard of the first corrugated layer may be as much as twice the thickness of the paperboard of the corruations of the second layer of corrugated material. Thus, in accordance with one aspect of the present invention, the physical properties exhibited by the first and second layers are substantially different. Nevertheless, this use of two layers of corrugated paperboard of differing physical properties provides for exceptional tensile and burst strength, rupture and torque resistance, rigidity and other desirable physical properties of the laminate while minimizing the overall weight and bulkiness of the laminate.

The core with its overlaid top and bottom layers of linerboard defines a sheet 46 suitable for use in the present invention. For use in the present invention, commonly this sheet is cut into appropriately sized substantially rectangular units 48. Preferably, in the cut units, the corrugations are oriented to run between the opposite sides 50,52 of the cut unit, i.e., perpendicular to the longitudinal centerline 35 of the laminated rectangular cut unit.

In the depicted embodiment of FIG. 3 a further layer 44 of paperboard of about 0.18 inch thickness and about 69 lbs. Mullen is overlaid on a first outer flat planar surface 54 of the core and overwrapped about the girth of a cut unit 48 of the core. Among other things, this overlaid layer of paperboard closes the cut ends of the corrugations and fully encapsulates the core (other that its opposite end edges). This overwrap layer is bonded to all surfaces of the core which are covered by this overlaid layer, thereby enhancing various of the physical properties of the cut unit, such as torque resistance, puncture resistance, burst strength and tensile strength. As desired, this overlaid layer of paperboard may be coated or otherwise treated to enhance its physical properties, such as strength, puncture resistance, and/or other physical properties thereof. These enhanced properties of the overlaid layer are imparted to the underlying core so that the overall laminated unit exhibits like enhanced physical properties, all without adding materially to the overall weight of the laminate. Moreover, if desired this overlaid layer may be printable or otherwise made susceptible to the adhesive application thereto of labels, logos and/or fully printed paperboard sheets.

In the latter instance, as depicted in FIG. 4, one surface of the laminate may be overlaid with a printed still further layer 45 of coated paperboard, with the side edges of the added layer overwrapping the side edges of the laminate and/or the end edges of the laminate and having its perimetral margin 58 overlying the perimetral margin 60 of the laminate. This still further layer may be bonded to the laminate employing conventional adhesives. In this embodiment, that portion of the surface 54 of the laminate which is not overlaid by the perimetral margins of the printed layer may serve as the location of carpet samples mounted on the laminate. Again, this layer overwrapping the laminate contributes to the desired overall physical properties of the laminate without significantly adding to the overall weight of the laminate.

Alternatively, the exposed portion of the surface 54 of the laminate may be provided with a decorative overlay 62, such as a pattern of intersecting ribs 64 in the nature of a window with multiple panes. In this embodiment, each “pane” is adapted to receive therein a relatively small carpet sample 68. This embodiment is especially useful where the carrier is designed in the form of a planar laminate having one end 70 thereof folded back over upon itself, and anchored as by fasteners 72, 74 to the laminate.

As further depicted in FIG. 7, the back folding of the top end of the laminate defines a type of planar flap along the first end of the panel, such flap including a first portion which overlies a portion of the front surface of the first end of the planar panel. Preferably, the overfolded portion of the panel is anchored to the panel itself as by means of suitable removable fasteners 72, 74, such as bolt and nuts, which extend through the overlaid portion of the laminate and the immediately underlying portion of the laminate itself. As noted and depicted in FIG. 7, the top edge of the over-folded portion of the laminate may be provided with a handle such that the carrier, loaded with multiple carpet samples may be hand carried in a vertical attitude. In this embodiment of the present invention a plurality of samples may be affixed to the carrier within respective ones of “panes” defined by intersecting ribs that are bonded to the exposed surface of the laminate. The opposite surface of the carrier therefore is available for the application thereon of advertising and/or other printed information.

In one embodiment, as depicted in FIG. 6, in lieu of using “panes” for display of multiple relatively small carpet samples, the top ends of multiple relatively large carpet samples may be anchored between the first portion of the flap and the top end of the planar panel as by conventional fasteners which extend through the first portion of the flap, through the carpet samples, thence through the first end of the planar panel. As needed, the fasteners may project from the rear surface of the planar panel for attachment of removable anchors for the fasteners. As noted, a handle may be provided on the uppermost surface of the second portion of the flap for one-hand transport of the carrier and its carpet samples from place to place. In this embodiment, the overall length of the carrier is chosen to permit the carrier and its samples to be fully extended downwardly, but terminating short of the ground or other surface over which a person may carry the carrier when grasped in one hand on the fully extended arm of the person. In one embodiment, the full vertical length of the carrier and its samples does not exceed about 24 inches.

When employing the carrier to transport relatively large size carpet samples which drape from the top end of the carrier, the folded back edge of the carrier may be sized to permit the mounting of the top ends of a plurality of carpet samples within the folded back region of the laminate so that these samples drape freely downwardly from the folded back region. As depicted in FIG. 7 to this end, the top end 70 of the laminate may be provided with first and second fold grooves 82,84 respectively, which extend between the opposite side edges 50,52 of the laminate. In the present invention, each such fold groove is cut into the thickness of the laminate such that paperboard is removed from the laminate to define a fold groove having a substantially rectangular cross-sectional area which is substantially free of paperboard (See also FIG. 3). In the preferred embodiment, each groove is limited in depth. Specifically, in the cutting away of the paperboard to define the groove, only portions of those layers disposed outwardly of the intermediate linerboard layer 22 disposed between the two layers of corrugated paperboard is removed, leaving the remainder of the thickness of the laminate intact. Each such groove is between about ¼ and 5/16 of an inch in width and about 0.150 inches in depth and extends fully between the opposite side edges of the laminate.

Referring to FIG. 11, in another embodiment of the present invention, the carrier of the present invention comprises a unitary single planar panel formed of the paperboard laminate 14 of the present invention and having front and rear flat planar surfaces 86 and 88, respectively, first and second side edges 90 and 92, respectively, and first and second end edges 94 and 96, respectively.

One such embodiment is depicted in FIG. 12 and comprises a “book” 98 having first, second and third planar panels 100, 102 and 103, respectively, each panel including a front and rear surface 106 and 108, respectively. The panels are integrally formed from a single unitary cut unit of a paper-based laminate 14 which is provided with two sets 110, 112 of multiple fold grooves which extend between the opposite side edges of the laminate at locations between the first and second panels 100, 102 and between the second and third panels 103, 104. In this “book” embodiment of the present invention, the covered laminate is provided with a set of two parallel spaced apart fold grooves at each of two locations along the length dimension of the laminate, more specifically at locations spaced from respective ones of the opposite ends of the laminate a distance of about one-third of the overall length of the laminate. These sets of two parallel fold grooves effectively divide the length of the laminate into three substantially equal panels. Thus, the third panel may be folded back upon the second panel and the first panel may be folded back upon the third panel.

Each of the first and second panels includes at least one carpet sample 114 affixed to at least the front surface of respective panels. The third panel includes carpet samples n both its front and rear surfaces. Thus, when the panels of the carrier are folded back upon one another, with the third panel being most central, the samples on the front and rear surfaces of the third panel overlie the samples on the front surfaces of the first and second panels.

Each fold groove exhibits a generally rectangular lateral cross-section as seen in FIG. 3. Each groove is formed by cutting away a portion of the laminate commencing on the inner second surface of the laminate and extending into the thickness of the laminate to terminate proximate, but short of, that layer of linerboard which is disposed intermediate said first and second layers of corrugated paperboard. The two fold grooves of the first set of og fold grooves are spaced apart by a distance substantially equal to the anticipated thickness of the two layers of carpet samples plus the approximate thickness of the laminate. It has been found that this form and spacing of the grooves provides excellent foldability of the third panel back upon, but spaced apart from, the second central panel and foldability of the first panel back upon, but spaced apart from, the third panel, thereby capturing the third panel between the second and first panels, all when carpet samples are mounted on the second outer surface of the first and second panels and on both the front and rear surfaces of the third panel.

This “book” carrier is of substantially the same laminate construction as the flat planar carrier of the type described hereinabove. In either instance the carrier is suitable to have mounted thereon one or more carpet samples in a manner which permits the carrier and its affixed carpet samples to be mobile in that the carrier is significantly light in its overall weight, but is inordinately resistant to flexing, tearing, rupture or similar destructive forces both during transport of the carrier and during placement of the carpet samples adjacent other decor of a home or office, for example, which is remote from a retail or wholesale outlet for the carpet displayed via the present invention. 

1. A carrier for mobile display of carpet samples comprising a laminate constructed essentially of paper, including a first outer layer of linerboard having a thickness of between about 0.014 and about 0.020 inch and a burst strength of between about 65 lbs and about 75 lbs as determined employing a conventional Mullen tester, a first inner layer of corrugated paperboard, having not less than 8 flutes per inch, each flute having a peak to valley height of about 0.085 inch, and having a burst strength of not less than about 23 lbs, the peaks of said flutes of said first inner layer of corrugated paperboard being bonded to said first outer layer of linerboard, a second layer of linerboard having a thickness of between about 0.010 and about 0.016 inch, the valleys of said flutes of said first inner layer of corrugated paperboard being bonded to said second layer of linerboard, a second inner layer of corrugated paperboard having between about 5 and about 20 flutes per inch, each flute having a peak to valley height of about 0.065 inch, the peaks of said flutes of said second inner layer of corrugated paperboard being bonded to said second layer of paperboard, a second outer layer of linerboard disposed opposite said first outer layer of linerboard, having a thickness of between about 0.014 and about 0.020 inch, and said valleys of said second layer of corrugated paperboard being bonded to said second outer layer of linerboard, thereby defining a flat planar paperboard laminate having opposite flat top and bottom planar outer surfaces, opposite side edges and opposite end edges, and exhibiting a burst strength of 400 lbs.
 2. The carrier of claim 1 further including at least one fold line extending between opposite side edges of said planar laminate proximate one end thereof, said fold line being characterized by the absence of said first layer of linerboard and said flutes of said first layer of corrugated paperboard within the bounds of said fold line and minimal deformation of said second layer of corrugated paperboard.
 3. The carrier of claim 1 including a fourth layer of linerboard overlying and bonded to said top planar surface of said laminate, overwrapping said side opposite side edges of said laminate, and defining a perimeter on said bottom planar surface of said laminate.
 4. The carrier of claim 3 wherein said fourth layer exhibits a burst strength of about 50 lbs.
 5. The carrier of claim 4 and including a fifth layer of linerboard overlying and bonded to said bottom planar surface of said laminate, said fifth layer of linerboard having a thickness of about 0.008 inch and covering any exposed edges of said perimeter of said fourth layer of linerboard which may be exposed on the bottom surface of said laminate.
 6. The carrier of claim 4 wherein said fourth layer of linerboard includes an outer surface and further including a coating applied at least said outer surface.
 7. The carrier of claim 6 wherein said outer coating is printable employing conventional printing techniques.
 8. The carrier of claim 5 and including a plurality of carpet samples affixed to at least said fifth layer of linerboard.
 9. The carrier of claim 8 and including at least one further carpet sample affixed to said planar bottom surface of said laminate.
 10. A system for mobile display of multiple carpet samples comprising a carrier, said carrier including a first outer layer of linerboard having a thickness of between about 0.014 and about 0.020 inch and a burst strength of between about 65 lbs and 75 lbs as determined employing a conventional Mullen tester, a first inner layer of corrugated paperboard, having between about 8 and about 12 flutes per inch, each flute having a peak to valley height of about 0.085 inch, said first inner layer of corrugated paperboard having a burst strength of not less than about 23 lbs, the peaks of said flutes of said first inner layer of corrugated paperboard being bonded to said first outer layer of linerboard, a second layer of linerboard having a thickness of between about 0.010 and about 0.016 inch, a second inner layer of corrugated paperboard having between about 15 and about 20 flutes per inch, each flute having a peak to valley height of about 0.065 inch, said second layer of linerboard being interposed between, and bonded to, the valleys of said first layer of corrugated paperboard and the peaks of said flutes of said second layer of corrugated paperboard, a third layer of linerboard, having a thickness of between about 0.014 and about 0.020 inch, said third outer layer of linerboard being disposed in overlying relationship to, and bonded to, said first outer layer of linerboard, thereby defining a flat planar unitary laminate having top and bottom opposite surfaces, first and second opposite side edges, and first and second opposite end edges, and exhibiting a burst strength of not less than 350 lbs, said laminate further including at least one fold line extending between opposite side edges of said planar laminate, and said fold line being characterized by the absence of said first layer of linerboard and said flutes of said first layer of corrugated paperboard within the bounds of said fold line and minimal deformation of said second layer of corrugated paperboard.
 11. The system of claim 10 and including a fourth layer of linerboard overlying, overwrapping and bonded to at least a planar top surface and opposite of said laminate.
 12. The system of claim 11 wherein said fourth layer exhibits a burst strength of about 50 lbs.
 13. The system of claim 11 wherein said fourth layer of linerboard includes an outer surface and further including a coating applied at least said outer surface.
 14. The system of claim 13 wherein said outer coating is printable employing conventional printing techniques.
 15. The system of claim 15 and including a plurality of carpet samples affixed to at least said fourth layer of linerboard.
 16. The system of claim 15 and including at least one further carpet sample affixed to said planar bottom surface of said laminate.
 17. A system for mobile display of multiple carpet samples comprising a carrier formed essentially of paper for mounting of said carpet samples thereon for storage or transport, said carrier comprising a laminate including a central core formed from a first outer layer of linerboard, a first layer of corrugated paperboard having corrugations of a first size and spacing and a second layer of corrugated paperboard having corrugations of a second size and spacing, said corrugations of said first layer being of a larger size and greater spacing than said corrugations of said second layer of corrugated paperboard, an inner layer of linerboard interposed between said first and second layers of corrugated paperboard and bonded to the valleys of the flutes of said first layer of corrugated paperboard and to the peaks of the flutes of said second layer of corrugated paperboard, a second outer layer of linerboard overlying and bonded to the peaks of said flutes of said first layer of corrugated paperboard, a third outer layer of linerboard overlying and bonded to the valleys of said first layer of corrugated paperboard, a further outer layer of linerboard disposed in overlying and bonded relationship to said third outer layer of linerboard, and a still further layer of paperboard overlying and bonded to said further outer layer of linerboard and overwrapping and bonded to at least the opposite side edges of said laminate and further extending into overlying and bonded relationship to at least the perimetral margins of said third outer layer of linerboard.
 18. The system of claim 17 and including at least one fold groove extending between opposite side edges of said laminate, said fold groove being characterized by the absence of paperboard or linerboard within the bounds of said fold groove. 